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NCS Auto Mechanic Revised

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NATIONAL COMPETENCY STANDARDS

FOR
AUTOMOBILE MECHANIC
(NC1, NC2 & NC3)

Department of Occupational Standards


Ministry of Labour and Human Resources
Thimphu, Bhutan

(Revised – 2012)
NATIONAL COMPETENCY STANDARDS
FOR
AUTOMOBILE MECHANIC
(NC1, NC2, NC3)

Department of Occupational Standards


Ministry of Labour and Human Resources
Thimphu, Bhutan.
First Publication 2009
First Revision 2012
(C) Department of Occupational Standards (DOS), MoLHR.
FOREWORD

The Department of Occupational Standards of the Ministry of Labour and


Human Resources proudly presents the revised version of the National
Competency Standards (NCS) for Automobile Mechanic (Light Vehicle) as a
major initiative for improving the quality of Vocational Education and Training
System in Bhutan. These revised versions of the standards represent the fruits
of hard work and invaluable experiences gained by the department since its
establishment in the latter half of 2003. The main aim of developing National
Competency Standards is to set up a well defined nationally recognized
Vocational Qualification and Certification system that will help set a
benchmark for the Vocational Education and Training (VET) System in our
country aligned to international best practices.
National Competency Standards is one of the base pillars in the Bhutan
Vocational Qualification Framework (BVQF) and is the first step in its
implementation. The standards are developed / revised to ensure that
employees or vocational graduates possess and acquire the desired skills,
knowledge and attitude required by industries and employers. In order to
ensure this close match in supply and demand of skills, knowledge and
attitude, standards have been developed in close consultation and partnership
with industry experts and validated by the Technical Advisory Committees for
the concerned economic sectors.
A vocational education and training system based on National Competency
Standards shall ensure that delivered training is of a high quality and relevant
to the needs of the labour market. As a result, future VET graduates will be
better equipped to meet the need and expectations of industries and
employers. This positive impact on the employability of VET graduates will
enhance the reputation of vocational education and training and make it
attractive to school leavers.
While acknowledging the existing level of cooperation and collaboration, the
ministry earnestly requests employers and training providers to extend the
fullest support and cooperation in implementing the National Competency
Standards. The ultimate objective is to build a competent and productive
national workforce that will contribute to the continued socio-economic
progress of our country.
I gratefully acknowledge the valuable contributions made by experts from
industries during the consultation, verification and validation processes of the
standards. I look forward to improved engagement and active participation of
the industry and employers in the development of a quality assured demand
driven VET system in the near future.
I firmly believe we can sacrifice a bit today for a better tomorrow.

Sonam Rinchen
Director
i
INTRODUCTION

A. National Competency Standards (NCS)

National Competency Standards specify the skill, knowledge and attitudes


applied to a particular occupation. Standards also specify the standards or
criteria of performance of a competent worker and the various contexts in
which work may take place. Standards provide explicit advice to assessors
regarding the skill and knowledge to be demonstrated by candidates seeking
formal recognition either following training or through work experience.

Purpose of National Competency Standards

Competency Standards serve a number of purposes including:


 Providing advice to curriculum developers about the skill and knowledge
to be included in curriculum.
 Providing specifications to assessment resource developers about the
skill, knowledge and attitudes within an occupation to be demonstrated by
candidates.
 Providing advice to industry/employers about job functions, which in turn
can be used for the development of job descriptions, performance
appraisal systems and work flow analysis.

ii
B. Bhutan Vocational Qualification Framework (BVQF)

Bhutan Vocational Qualifications Framework is an agreed system of


Assessing, Certifying and Monitoring nationally recognized qualifications for all
learning in the VET sector against national standards, in training institutions, in
the workplace, in schools or anywhere where learning takes place.

Components of the Bhutan Vocational Qualification Framework (BVQF)

NATIONAL COMPETENCY STANDARDS

COMPETENCY BASED
CURRULUM
ASSESSMENT
RESOURCES
TRAINING PROGRAMME

WORKERS FROM
COMPETENCY BASED ASSESSMENT *RPL
WORK PLACE

CERTIFICATION

CERTIFIED SKILLED WORKER

INDUSTRY / LABOUR MARKET

* RPL = Recognition of Prior Learning

iii
BVQF Levels

The Bhutan Vocational Qualification Framework has three levels classified


based on the competency of the skilled workers. The three levels are:

 National Certificate Level 3 (NC III) - Master Craftsman


 National Certificate Level 2 (NC II) - Craftsman
 National Certificate Level 1 (NC I) - Semi Skilled Worker

BVQF Level Descriptors

The qualification levels are decided based on level descriptors. The detail of
the qualification level descriptor is as follows:

National Certificate Level 1 (Semi skilled)

Carry out processes Learning demand: Responsibilities


that: which are applied:
 Are narrow in range.  Basic operational  In directed activity.
 Are established and knowledge and skill.  Under general
familiar.  Utilization of basic supervision and
 Offer a clear choice available information. quality control.
of routine  Known solutions to  With some
responses. familiar problems. responsibility for
 Involve some  Little generation of quantity and quality.
prioritizing of tasks new ideas.  With no responsibility
from known for guiding others.
solutions.

National Certificate Level 2 (Craftsman)

Carry out processes Learning demand: Responsibilities


that: which are applied:
 Require a range of  Some relevant  In directed activity
well developed theoretical knowledge. with some autonomy.
skills.  Interpretation of  Under general
 Offer a significant available information. supervision and
choice of  Discretion and quality checking.
procedures judgement.  With significant
requiring  A range of known responsibility for the
prioritisation. responses to familiar quantity and quality
 Are employed within problems of output.

iv
a range of familiar  With some possible
context. responsibility for the
output of others.
National Certificate Level 3 (Master Craftsman)

Carry out processes Learning demand: Responsibilities


that: which are applied:
 Requires a wide  A broad knowledge  In self–directed
range of tech-nical base which activity.
or scholastic skills. incorporates some  Under broad
 Offer a considerable theoretical concepts. guidance and
choice of procedures  Analytical evaluation.
requiring prioriti- interpretation of  With complete
zation to achieve information. responsibility for
optimum outcomes.  Informed judgement. quantity and quality
 Are employed in a  A range of of output.
variety of familiar sometimes innovative  With possible
and unfamiliar responses to responsibility for the
contexts. concrete but often output of others.
unfamiliar problems.

v
PURPOSE

This suite of three qualifications is designed for people interested in a career


in the motor industry as an Auto Mechanic.

The first of the qualifications is the National Certificate in Automobile Mechanic


Level 1. It provides school leavers with generic and industry specific skills and
demands a level of performance that will enable new recruits to the industry to
be immediately productive.

The qualification comprises four units of Competency Standards that cover the
essential knowledge and skills required of auto mechanics in performing works
related to servicing suspension system, steering system, brake system and
clutch system of automobiles.

The National Certificate in Automobile Mechanic Level 1 prepares people for


entry into further qualifications in the motor industry and is a prerequisite for
entry into the National Certificate Level 2.

The National Certificate in Auto Mechanic Level 2 is the intermediate level


qualification in this set. Candidates wishing to be admitted into training will
already hold the National Certificate in Auto Mechanic Level 1. The Level 2
qualification recognizes the skills and knowledge required for people working
as a skilled auto mechanic and builds on the skills and knowledge that
candidates will have gained through the successful completion of the Level 1
certificate.

The qualification includes five units of Competency Standards that cover


knowledge and skills required in performing overhaul of power or drive train,
servicing of engine auxiliary systems, performing spark ignition (SI) engine
tune-up, performing diesel engine tune-up and performing basic auto electrical
works. It is a prerequisite for entry into the Level 3 qualification.

The National Certificate in Auto Mechanic Level 3 is currently the final


achievement in this qualification pathway. Candidates wishing to be admitted
into training will already hold the National Certificate in Auto Mechanic Level 2.

The Level 3 qualification recognizes the competencies required to work as a


highly skilled auto mechanic whose primary focus is the overall servicing and
repair of motor vehicles. The only unit of Competency Standard included in
the Level 3 National Certificate is the knowledge and skills required to perform
overhaul of automotive engine.

vi
PACKAGING OF QUALIFICATIONS FOR
AUTOMOBILE MECHANIC

The National Competency Standard for the Automobile Mechanic (L/V)


comprises 10 units of competency standard, which are grouped to form three
qualification levels, are as shown below:
National Certificate Level 3

Overhaul engine (7231-U10-L3)

National Certificate Level 2

Perform basic auto electrical works (7231-U9-L2)

Perform diesel engine tune-up (7231-U8-L2)

Perform spark ignition (SI) engine tune-up (7231-U7-L2)

Service engine auxiliary system (7231-U6-L2)

Overhaul power or drive train (7231-U5-L2)

National Certificate Level 1

Service clutch system (7231-U4-L1)

Service brake system (7231-U3-L1)

Service steering system (7231-U2-L1)

Service suspension system (7231-U1-L1)

ENTRY

vii
CODING USED FOR NATIONAL COMPETENCY STANDARDS

The coding and classification system developed in Bhutan is logical, easy to


use, and also aligned with international best practises. The Bhutanese coding
and classification system is based on the International Standard Classification
of Occupations, 2008 (ISCO-08) developed by the International Labour
Organisation (ILO).

The coding of the national competency standards forms the basis of the
identification code for the Vocational Education and Training Management
Information System (VET – MIS) both in terms of economic sector
identification and that of the individual standard.
Coding the individual units of competency standard is to identify the level in
qualification packages to which it belongs.

While packaging, in order to follow a logical order, only competency standards


related to each other and following a logical sequence in terms of training
delivery, from the simple to the complex, are clustered into a qualification
packages.

The ILO assigns the code 7231 to the occupation of Auto mechanic and
related trades. Therefore, in the Bhutan context, the occupation Auto
Mechanic has been assigned the code 7231 in the National Coding System.
The first unit is assigned the code U1, the first Unit of Competency Standard
clustered into the first qualification is designated the code 7231-U1. Levels are
assigned the code L and follow a logical progression from the National
Certificate Level 1 (NC I) to the National Certificate Level 3 (NC III). Therefore
the National Certificate Level 1 is assigned the code L1. The complete unit
code will be 7231-U1-L1.

viii
Implementation and Operational Procedures for National Competency
Standards (MoLHR)

Occupational Profile development (DOS and


industry stakeholders)

National Competency Standards (DOS and


industry experts)

National Qualification (assigned by DOS)

Program Design

Program Registration and Accreditation

Program Implementation (Training Providers)

National Assessment (DOS)

Certification (DOS)

Key:

MoLHR – Ministry of Labour and Human Resources


DOS – Department of Occupational Standards
ix
NATIONAL COMPETENCY STANDARDS FOR AUTO MECHANIC
rd
Validation date : 23 November 2012.
th
Endorsement date : 4 December 2012.
th
Date of Review : 4 December 2015 (Max. 3 years).

Technical Advisory Committee (TAC) members for the Automobile


Sector involved in the validation of NCS for Automobile Mechanic:

1. Bhim Raj Gurung (TAC Chairman), Manager, Kancha Automobile


Workshop, Thimphu.
2. Dawa Drukpa, Manager, Tashi Engineering Workshop,
Phuentsholing.
3. Sangay Wangchuk, Principal, Technical Training Institute,
Samthang.
4. Gyem Dorji, Head of Department, Technical Training Institute,
Thimphu.
5. Lhatu Dorji, Proprietor, L. D Engineering Workshop, Phuentsholing.
6. Tshewang Lham, Manager, Zimdra Automobiles, Phuentsholing.
7. Lhundup Dorji, Asst. RTO, Road Safety and Transport Authority,
Thimphu.
8. Karma Dorji, Senior Programme Officer, Training and Professional
Services Division, Department of Human Resources, MoLHR,
Thimphu.
9. Karma Loday (TAC Member Secretary), Chief Programme Officer,
Standards and Qualification Division, Department of Occupational
Standards, MoLHR, Thimphu.

x
Subject experts (auto mechanic) involved during the consultation
workshop to revise the NCS for Auto Mechanic:

1. Dawa Dakpa, Manager, Tashi Engineering Workshop, Phuentsholing.


2. Ugyen Dorji, Trainer, Technical Training Institute, Samthang.
3. Sonam Tobgay, Trainer, Technical Training Institute, Thimphu.
4. Nima Tshering, Mechanic, State Trading Corporation of Bhutan Limited,
Phuentsholing.
5. Deepak Gurung, Mechanic, Gangkhap Engineering Workshop,
Phuentsholing.
6. Bhim Kumar Pokwal, Mechanic, Zimdra Automobiles, Phuentsholing.
7. Nirmal Sariba, Mechanic, Wangdi Engineering Workshop,
Phuentsholing.
8. Tapas Sarkar, Mechanic, Druk Penden Engineering Workshop,
Phuentsholing.

1. Tshewang, Senior Programme Officer (Facilitator),


Department of Occupational Standards (DOS), MoLHR, Thimphu.

xi
TABLE OF CONTENTS – COMPETENCY STANDARDS FOR
AUTOMOBILE MECHANIC

NATIONAL CERTIFICATE – LEVEL 1

UNIT TITLE ELEMENTS OF COMPETENCE PAGE

Service 1. Diagnose suspension system failures.


suspension 1
2. Replace faulty suspension components.
system

Service steering 1. Perform wheel alignment.


system
2. Service steering system.
4
3. Perform wheel balancing
4. Analyze kingpin condition

Service brake 1. Diagnose faults in brake system.


system
2. Overhaul and service brake system 8
components.
3. Adjust brake system.

Service clutch 1. Overhaul and service clutch mechanism.


system 11
2. Adjust clutch system.

xii
NATIONAL CERTIFICATE – LEVEL 2

UNIT TITLE ELEMENTS OF COMPETENCE PAGE

Overhaul power 1. Diagnose transmission failure.


or drive train
2. Service transmission components.
3. Service propeller shaft components.
4. Service final drive and differential 15
components.
5. Service wheel bearings and components.
6. Service drive or axle shaft components.

Service engine 1. Service cooling system


auxiliary system
2. Service lubricating system.
20
3. Service petrol fuel system.
4. Service diesel fuel system.

Perform spark 1. Service air / fuel system.


ignition (SI)
2. Check and test ignition system.
engine tune-up
3. Check and adjust drive belt.
24
4. Check engine compression.
5. Check and adjust engine speed.
6. Check valve tappet clearance.

Perform diesel 1. Service air / fuel injection system.


engine tune-up
2. Service drive belt.
27
3. Check engine compression.
4. Check valve tappet clearance.

Perform basic 1. Inspect and replace basic electrical


auto electrical components. 30
works
2. Service batteries and jump start vehicle.

xiii
NATIONAL CERTIFICATE – LEVEL 3

UNIT TITLE ELEMENTS OF COMPETENCE PAGE

Overhaul engine 1. Diagnose problems and dismount


engine. 34
2. Service engine.

xiv
AUTOMOBILE MECHANIC
COMPETENCY STANDARDS
FOR
NATIONAL CERTIFICATE LEVEL 1 (NC 1)

UNIT TITLE ELEMENTS OF COMPETENCE

Service suspension 1. Diagnose suspension system failures.


system
2. Replace faulty suspension components.

Service steering 1. Perform wheel alignment.


system
2. Service steering system.
3. Perform wheel balancing
4. Analyze kingpin condition

Service brake 1. Diagnose faults in brake system.


system
2. Overhaul and service brake system
components.
3. Adjust brake system.

Service clutch 1. Overhaul and service clutch mechanism.


system
2. Adjust clutch system.

xv
UNIT TITLE Service suspension system.

DESCRIPTOR This unit covers the competencies required to inspect


and replace the components of the suspension
system.

CODE 7231- U1- L1

ELEMENTS OF
PERFORMANCE CRITERIA
COMPETENCE

1. Diagnose 1.1 Identify symptoms that indicate suspension


suspension failure.
system
1.2 Identify the fault and recommend repair action
failures.
in accordance with standard practices.
1.3 Provide support to the vehicle to avoid
personal injury or damage to the vehicle as
per the job requirements
1.4 Check suspension components for defects
using tools and equipment and industry
accepted techniques.

2. Replace faulty 2.1 Dismount and mount suspension


suspension components as per service manual.
components.
2.2 Dismount components without damage to
other vehicle parts.
2.3 Disassemble and assemble suspension
components without causing damage to other
parts.
2.4 Service the disassembled components as
per the job requirements.
2.5 Replace damaged parts as specified in
service manual

1
RANGE STATEMENT

Tools and May include but not limited to:


equipment
Lift, support stand, grease dispenser, coil spring
compressor, heavy duty socket wrench, basic hand
tools, hydraulic press, torque wrench, hydraulic jack,
shock absorber testing equipment, puller.

Industry accepted Include but not limited to:


techniques
Drive test, visual inspection, audio test, diagnostic
equipment.

Suspension Includes:
components
Stabilizer bar and linkages, coil and leaf springs,
torsion bar, shock absorbers, suspension arms and
bushes, ball joints, control arms.

Service May include but not limited to:


Replace, Cleaning, Greasing

ASSESSMENT GUIDE

Form of assessment
 Continuous assessment together with collected evidence of
performance will be used.
 Evidence of the performance shall be based on practical
demonstration.
 Knowledge can be assessed through diagrams, in writing or orally
(viva-voce).
Assessment context
 Competency may be assessed in the actual work place or in a
simulated workplace setting.
Assessment condition
 The candidate shall have access to all required tools, equipment,

2
materials and documents.
 The candidate must complete the assessment in industry accepted time
frame.
Critical aspects
 Demonstrate compliance with safety regulation applicable to work site
operation.
 Identify defects and problems that occur and take necessary action to
rectify (uncomfortable or bumpy driving, noise when moving or stopped,
poor directional stability, shimming of the front wheel while steering at
high speed, pulling to one side while driving or braking, irregular tyre
wear) in accordance with standard practices.

UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS

 Operating principles of  Use of tools and equipment.


suspension system.
 Cleaning suspension parts.
 Types of suspension systems.
 Replacing suspension
 Personal protective equipment. components.
 Sealant and adhesives  Use of sealant and adhesives
 Types of cleaning solvent

3
UNIT TITLE Service steering system.

DESCRIPTOR This unit covers the competencies required to service


or overhaul a steering system, and perform wheel
alignment and wheel balancing.

CODE 7231-U2-L1

ELEMENTS OF
PERFORMANCE CRITERIA
COMPETENCE

1. Perform wheel 1.1 Perform visual inspections of tyre conditions


alignment and inflation.
1.2 Check steering linkages in accordance with
standard practices
1.3 Set up wheel alignment using equipment
according to the manufacturer’s specification.
1.4 Inspect and make necessary adjustments to
steering geometry according to the
manufacturer’s specification.

2. Service 2.1 Check steering system for wear and tear in


steering accordance with standard practices.
system.
2.2 Remove steering system components as per
standard procedures.
2.3 Dismantle and replace defective steering
components as per the standard practices.
2.4 Assemble and install the steering components
as per standard procedures.
2.5 Use personal protective equipment (PPE)
as per the job requirements.

3. Perform wheel 3.1 Mount the wheel on wheel balancing machine


balancing. as per standard procedures.
3.2 Identify balance weight location following
standard practices.
3.3 Adjust and balance the wheel as indicated by

4
the wheel balancing machine.

4. Analyze 4.1 Identify defective kingpin parts and


kingpin recommend corrective action as per the job
condition. requirements.
4.2 Dismantle kingpin as per service manuals.
4.3 Inspect and service kingpin parts as per
service manuals.
4.4 Participate in test drive to ensure proper
functioning.

RANGE STATEMENT

Equipment May include but not limited to:


Lift, support stand, heavy duty socket wrench, torque
wrench, basic hand tools, caster-camber gauge,
puller, wheel alignment equipment, wheel balancing
machine.

Steering geometry Includes but not limited to:


Positive and negative camber, toe-in and toe-out,
kingpin inclination.

Steering system May include but not limited to:


Re-circulating ball bearing type; worm and gear; rack
and pinion; power assisted steering (hydraulic,
electrical); steering linkages.

Wear and tear May include but not limited to:


Cracks, loose or broken parts, worn out.

Standard May include:


procedures /
Job card, requisition slip, gate pass.
practices

Personal Includes:
protective

5
equipment (PPE) Apron, gloves, safety shoes, workshop dress.

Service May include but not limited to:


Replacement, adjustment, cleaning, greasing

ASSESSMENT GUIDE

Form of assessment
 Continuous assessment together with collected evidence of
performance will be used.
 Evidence of the performance shall be based on practical
demonstration.
 Knowledge can be assessed through diagrams, in writing or orally
(viva-voce).
Assessment context
 Competency may be assessed in the actual work place or in a
simulated workplace setting.
Assessment condition
 The candidate shall have access to all required tools, equipment,
materials and documents.
 The candidate must complete the assessment in industry accepted time
frame.
Critical aspects
 Demonstrate compliance with safety regulation applicable to work site
operation.
 Identify defects and problems that occur and take necessary action to
rectify (Shoulder wear, centre wear, feather wear, manufacturing
defects, uneven wearing) in accordance with standard practices.

6
UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS

 Operating principles of steering  Accessing, interpreting and


system. applying technical information.
 Types of steering systems.  Safe handling of equipment and
tools.
 Manufacturer specifications.
 Use of sealant and adhesives
 Occupational Health and Safety
(OHS) Regulations.  Applying personal safety
procedures.
 Causes of defects in steering
system.  Interpersonal and
communication.
 Sealant and adhesives
 Team work.
 Types of solvent

7
UNIT TITLE Service brake system.

DESCRIPTOR This unit covers the competencies required to


diagnose, adjust, repair, and service a brake system.

CODE 7231-U3-L1

ELEMENTS OF
PERFORMANCE CRITERIA
COMPETENCE

1. Diagnose 1.1 Participate in road test to detect faulty brake


faults in brake system for different types of brake systems.
system.
1.2 Diagnose faults and recommend remedial
action.

2. Overhaul and 2.1 Remove and mount brake system


service brake components as per service manual.
system
2.2 Clean parts with solvent and materials as per
components.
job requirements.
2.3 Inspect parts for wear and tear of the
components and take necessary action.
2.4 Assemble the brake system components as
per the service manual.
2.5 Inspect condition and level of brake fluid and
replace if necessary as per the specifications.

3. Adjust brake 3.1 Bleed the brake system in accordance with


system. service manual.
3.2 Check the brake system components for
proper functioning.
3.3 Adjust the brake including the parking brake
as required in accordance with service
manual.
3.4 Adjust the brake pedal free play in
accordance with service manual.
3.5 Participate in road test to ensure brake
system is functioning properly

8
RANGE STATEMENT

Brake system Includes:


Different types of brakes – service brake, parking
brake, auxiliary brake.
Different brake systems – drum brakes, disc brakes,
and antilock braking system (ABS)
Different brake operation – pneumatic, hydraulic,
mechanical.

Brake system May include but not limited to:


components
Master cylinder (tandem and conventional), , drum,
brake pad, brake disc, brake shoe, brake calliper,
brake hoses, tubes, wheel cylinder kit, wheel cylinder,
springs, bleeding nipples, brake booster.

Materials Include:
Brake fluid, lithium grease, water paper, emery cloth

Brake fluid May include but is not limited to:


DOT 3, DOT 4, DOT 5, DOT 5.1.

ASSESSMENT GUIDE

Form of assessment
 Continuous assessment together with collected evidence of
performance will be used.
 Evidence of the performance shall be based on practical
demonstration.
 Knowledge can be assessed through diagrams, in writing or orally
(viva-voce).
Assessment context
 Competency may be assessed in the actual work place or in a
simulated workplace setting.

9
Assessment condition
 The candidate shall have access to all required tools, equipment,
materials and documents.
 The candidate must complete the assessment in industry accepted time
frame.
Critical aspects
 Demonstrate compliance with safety regulation applicable to work site
operation.
 Identify defects and problems that occur and take necessary action to
rectify.
 Bleeding and adjustment of brake in accordance with service manual.

UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS

 Basic operating principles of  Use of tools and equipment.


brake systems.
 Applying personal safety work
 Types of brake systems. practice.
 Occupational Health and Safety  Maintaining orderliness and
(OHS) Regulations. cleanliness.
 Manufacturer specifications.  Interpersonal and
communication.
 Range of brake fluids.
 Ability to work in a team.
 Types of solvent
 Pascal’s law

10
UNIT TITLE Service clutch system.

DESCRIPTOR This unit covers the competencies required to


maintain and replace damaged components of the
clutch system

CODE 7231-U4-L2

ELEMENTS OF
PERFORMANCE CRITERIA
COMPETENCE

1. Overhaul and 1.1 Indentify and diagnose clutch related failures


service clutch and recommend rectification procedures.
mechanism.
1.2 Dismount and mount clutch assembly as per
service manual.
1.3 Dismantle clutch system components
without causing damage to the parts or to the
vehicle.
1.4 Overhaul hydraulic clutch mechanism as per
service manual
1.5 Check the components of the clutch
mechanism and replace faulty components as
per standard procedures.
1.6 Check clutch fluid conditions and level, check
for any leakage, and rectify if necessary as
per standard procedures.

2. Adjust clutch 2.1 Adjust clutch in accordance with the service


system manual.
2.2 Bleed clutch system in accordance with
standard procedures.

RANGE STATEMENT

Clutch system Includes but not limited to:


components
Clutch cover assembly, clutch disc, clutch linkage,
clutch release bearing, pilot bearing, clutch release
11
fork, release spring, release fork adjuster, clutch
master cylinder, slave cylinder, release cylinder kits,
clutch cables

ASSESSMENT GUIDE

Form of assessment
 Continuous assessment together with collected evidence of
performance will be used.
 Evidence of the performance shall be based on practical
demonstration.
 Knowledge can be assessed through diagrams, in writing or orally
(viva-voce).
Assessment context
 Competency may be assessed in the actual work place or in a
simulated workplace setting.
Assessment condition
 The candidate shall have access to all required tools, equipment,
materials and documents.
 The candidate must complete the assessment in industry accepted time
frame.
Critical aspects
 Demonstrate compliance with safety regulations applicable to work site
operations.
 Troubleshoot and service clutch system in accordance standard
procedures
 Bleed / adjust clutch system in accordance with standard procedures.

12
UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS

 Types, function, and operation of  Interpreting and applying


clutch components. technical information.
 Clutch system adjustment.  Using relevant tools and
equipment.
 Hydraulic clutch mechanism,
function and operation.  Adjusting clutch components.
 Handling hydraulic fluids.  Applying personal safety
procedures.
 Occupational Health and Safety
(OHS) Regulations.  Ability to work in a team.
 Cause, symptoms and diagnose  Interpersonal and
of clutch system failures. communication
 Types of solvents
 Types of clutch plate materials
 Pascal’s law

13
AUTOMOBILE MECHANIC
COMPETENCY STANDARDS
FOR
NATIONAL CERTIFICATE LEVEL 2 (NC 2)
UNIT TITLE ELEMENTS OF COMPETENCE

Overhaul power or 1. Diagnose transmission failure.


drive train
2. Service transmission components.
3. Service propeller shaft components.
4. Service final drive and differential components.
5. Service wheel bearings and components.
6. Service drive or axle shaft components.

Service engine 1. Service cooling system


auxiliary system
2. Service lubricating system.
3. Service petrol fuel system.
4. Service diesel fuel system.

Perform spark 1. Service air / fuel system.


ignition (SI) engine
2. Check and test ignition system.
tune-up
3. Check and adjust drive belt.
4. Check engine compression.
5. Check and adjust engine speed.
6. Check valve tappet clearance.

Perform diesel 1. Service fuel injection system.


engine tune-up
2. Service drive belt.
3. Check engine compression.
4. Check valve tappet clearance.

Perform basic auto 1. Inspect and replace basic electrical components.


electrical works
2. Service batteries and jump start vehicle.

14
UNIT TITLE Overhaul power or drive train.

DESCRIPTOR This unit covers the competencies required to


diagnose, overhaul and test automatic and manual
transmissions, front and rear axles, and propeller
shafts.

CODE 7231-U5-L2

ELEMENTS OF
PERFORMANCE CRITERIA
COMPETENCE

1. Diagnose 1.1 Identify transmission failure symptoms in


transmission accordance standard procedures.
failure
1.2 Inspect the condition of the Automatic
Transmission Fluid (ATF), where applicable
following standard procedures.

2. Service 2.1 Drain transmission oil in accordance with


transmission standard procedures.
components
2.2 Disassemble and assemble transmission as
per standard procedures and tag
disassembled parts.
2.3 Inspect transmission for worn-out and
damaged parts, and measure backlash
following standard procedures.
2.4 Service component parts in accordance with
service manual.
2.5 Install transmission as per service manual.
2.6 Participate in road test following standard
procedures

3. Service 3.1 Diagnose propeller shaft problems following


propeller shaft standard procedures.
components
3.2 Dismount propeller shaft as per service
manual.
3.3 Dismantle or assemble propeller shaft
components in accordance with standard

15
procedures.
3.4 Inspect and service faulty parts and replace if
necessary in accordance with standard
procedures.
3.5 Participate in test drive following standard
procedures

4. Service final 4.1 Identify final drive and differential problems


drive and following standard procedures.
differential
4.2 Change differential oil in accordance with
components.
service manual.
4.3 Dismount the differential as per service
manual.
4.4 Identify and analyze defective parts and
recommend necessary remedial action.
4.5 Measure backlash, check correct gear mesh
of final drive, and interpret findings.
4.6 Dismantle differential parts as per service
manual and tag the dismantled parts.
4.7 Assemble and adjust parts as per service
manual and specifications using special
service tools (SST).
4.8 Participate in test drive following standard
procedures

5. Service wheel 5.1 Diagnose wheel bearing problems following


bearings and standard procedures.
components
5.2 Disassemble wheel hub and bearing as per
service manual using special service tools.
5.3 Identify and analyze defective parts and
recommend necessary remedial actions.
5.4 Assemble and adjust as per service manual
and specifications.
5.5 Measure preload and adjust in accordance
with service manual.
5.6 Participate in test drive following standard

16
procedures.

6. Service drive 6.1 Diagnose drive or axle shaft following


or axle shaft standard procedures.
components
6.2 Dismantle drive or axle shaft as per service
manual and tag the dismantled parts.
6.3 Identify and analyze the defective parts and
recommend remedial actions.
6.4 Service defective parts following standard
procedures.
6.5 Assemble as per service manual.
6.6 Participate in test drive following standard
procedures.

RANGE STATEMENT

Power train or Includes but not limited to:


drive train
Transmission, drive shaft, CV joint, propeller shaft,
centre bearing, cross bearing, spider kit, axle,
differential, transaxle, final drive.

Transmission Includes:
Automatic and manual; four (4) speed, five (5) speed,
and six (6) speed transmissions; transaxle
transmission.

Tools and Includes:


equipment
Lift/support stand, transmission jack, snap ring
expander (in/out), bearing puller, drift punch, basic
hand tools set, bench vice, special service tools
(SST), dial gauge, grease gun, oil gun, axle puller,
hydraulic press, torque wrench, pre-load gauge.

17
ASSESSMENT GUIDE

Form of assessment
 Continuous assessment together with collected evidence of
performance will be used.
 Evidence of the performance shall be based on practical
demonstration.
 Knowledge can be assessed through diagrams, in writing or orally
(viva-voce).
Assessment context
 Competency may be assessed in the actual work place or in a
simulated workplace setting.
Assessment condition
 The candidate shall have access to all required tools, equipment,
materials and documents.
 The candidate must complete the assessment in industry accepted time
frame.
Critical aspects
 Demonstrate compliance with safety regulations applicable to work site
operations.
 Troubleshoot transmission, drive shafts, differential, final drive and then
servicing following standard procedures.
 Adjustment of gears following standard procedures.

UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS

 Problems and causes in power  Reading, interpreting, and


or drive train. applying service manuals.
 Overhaul or repair procedures of  Use of proper tools and
power or drive train. equipment.
 Use of different types of  Checking power or drive train
lubricants or fluids. for normal operation drive.

18
 Operating principles of power  Applying personal safety
train or drive train. procedures.
 Equipment safety requirements.  Applying sealant and
adhesives.
 Personal safety procedures.
 Ability to work in a team.
 Sealant and adhesives
 Types of solvent
 Difference between differential
and final drive
 Gear ratio

19
UNIT TITLE Service engine auxiliary system.

DESCRIPTOR This unit covers the competencies required to service


the cooling, lubricating, and fuel systems in petrol and
diesel engines.

CODE 7231- U6-L2

ELEMENTS OF
PERFORMANCE CRITERIA
COMPETENCE

1. Service 1.1 Diagnose faulty components of cooling


cooling system in accordance with standard practices.
system.
1.2 Service cooling system components as per
the service manual.
1.3 Replace faulty parts and coolant as per the
manufacturer’s specifications.
1.4 Change and adjust the fan belt tension to the
specified tension as per the service manual
1.5 Check and rectify the stray current in
accordance with standard operating
procedures

2. Service 2.1 Check pressure, level, and condition of engine


lubricating oil as per owner’s manual.
system.
2.2 Perform oil flushing, if necessary as per
service manual instructions.
2.3 Change engine oil and filter following standard
procedures.
2.4 Service lubricating system components as
per the service manual
2.5 Run the engine and check for leakage
following standard procedures

3. Service petrol 3.1 Inspect fuel filter for clogging and replace if
fuel system. necessary following standard procedures.
3.2 Inspect fuel pipes for leakage or damage and
replace if necessary following standard
20
procedures.
3.3 Service or repair carburettor according to
manufacturer’s service manual.
3.4 Inspect and service injectors and replace if
necessary following standard procedures.
3.5 Inspect and repair fuel pump according to
service manual.
3.6 Inspect exhaust gas emission and perform
adjustment in accordance with set standard.

4. Service diesel 4.1 Inspect fuel filter for clogging and replace if
fuel system. necessary following standard procedures.
4.2 Inspect fuel pipes for leakage and damage
and replace if necessary following standard
procedures.
4.3 Participate in servicing or replacing pump
components as per the job requirements.
4.4 Inspect, service or replace, and adjust fuel
injector and components according to service
manual.
4.5 Inspect exhaust gas emission and perform
necessary adjustment in accordance to set
standard.

RANGE STATEMENT

Cooling system May include but not limited to:


components
Coolant, radiator, thermostat, fan, radiator cap, water
pump, hoses, fan belt, temperature gauge or sensors.

Lubricating system May include but not limited to:


components
Sensors, engine flushing oil, engine oil (as per
specifications), engine oil filter.

Petrol fuel system May include but not limited to:

21
components Sensors, filter, pumps, tubes, injectors, common rail
distribution injection (CRDI).

Diesel fuel system May include but not limited to:


components
Sensors, filter, pumps, tubes, injectors, common rail
distribution injection (CRDI).

ASSESSMENT GUIDE

Form of assessment
 Continuous assessment together with collected evidence of
performance will be used.
 Evidence of the performance shall be based on practical
demonstration.
 Knowledge can be assessed through diagrams, in writing or orally
(viva-voce).
Assessment context
 Competency may be assessed in the actual work place or in a
simulated workplace setting.
Assessment condition
 The candidate shall have access to all required tools, equipment,
materials and documents.
 The candidate must complete the assessment in industry accepted time
frame.
Critical aspects
 Demonstrate compliance with safety regulations applicable to work site
operations.
 Troubleshoot and service engine auxiliary system in accordance with
service manual.

22
UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS

 Principle and operation of  Using and interpreting service


cooling system. manuals.
 Principle and operation of  Diagnosing engine faults.
lubricating system.
 Applying personal safety
 Type of fuel, oil and their procedures.
specifications.
 Applying sealant and adhesives
 Fuel system basic principle and
operation.  Interpersonal and
communication.
 Quality of engine oil, coolant and
characteristics.  Ability to work in a team.

 Occupational Health and Safety


(OHS) Regulations.
 Function of Positive Crankcase
Ventilation (PCV).
 Types of solvent
 Sealant and adhesives

23
UNIT TITLE Perform spark ignition (SI) engine tune-up.

DESCRIPTOR This unit covers competencies required to carry out


spark ignition (SI) engine maintenance to the vehicle
at optimum engine performance.

CODE 7231-U7-L2

ELEMENTS OF
PERFORMANCE CRITERIA
COMPETENCE

1. Service air / 1.1 Check fuel pump for pressure and leakage
fuel system. using pulsation damper for Electronic Fuel
injection (EFI) system, and carburettor system
following standard procedures.
1.2 Service fuel system components following
standard procedures.
1.3 Service air system components following
standard procedures
1.4 Service exhaust system components
following standard procedures

2. Check and 2.1 Inspect distributor and CB point for wear,


test ignition service or replace as necessary.
system.
2.2 Test HT cable and ignition coil for required
resistance.
2.3 Service ignition system components
following standard procedures.

3. Check and 3.1 Check drive belt for defects or tension


adjust drive following standard procedures.
belt.
3.2 Adjust drive belt tension to specified tension
and replace if worn out following standard
procedures.

4. Check engine 4.1 Conduct compression test using compression


compression. gauge.
4.2 Interpret compression test result and take
necessary actions in accordance with
24
standard procedures.

5. Check and 5.1 Check idle speed following standard


adjust engine procedures.
speed.
5.2 Adjust idle speed (rpm) following standard
procedures

6. Check valve 6.1 Check valve tappet clearance as per service


tappet manual.
clearance
6.2 Set valve tappet clearance as per the service
manual.

RANGE STATEMENT

Fuel system Includes but not limited to:


components
Fuel injection pumps (FIP), electrical pump,
mechanical pump, fuel injector, fuel filter, feed pump
and carburettor.

Air system Includes but not limited to:


components
Air filter, ail filter case, air flow sensors.

Ignition system May include but not limited to:


components
Distributor, ignition coil, HT cable, spark plug,
transistorized ignition system.

Exhaust system May include but not limited to:


components
Exhaust manifold, turbo charger, exhaust pipe,
catalytic converter, silencer box.

ASSESSMENT GUIDE

Form of assessment
 Continuous assessment together with collected evidence of
performance will be used.

25
 Evidence of the performance shall be based on practical
demonstration.
 Knowledge can be assessed through diagrams, in writing or orally
(viva-voce).
Assessment context
 Competency may be assessed in the actual work place or in a
simulated workplace setting.
Assessment condition
 The candidate shall have access to all required tools, equipment,
materials and documents.
 The candidate must complete the assessment in industry accepted time
frame.
Critical aspects
 Demonstrate compliance with safety regulations applicable to work site
operations.
 Perform spark ignition (SI) engine tune up following standard
procedures.

UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS

 Process of engine tune up.  Reading, interpreting and


applying service manual
 Basic auto electrical and instruction.
electronics
 Using tools and equipment
 Types of lubricants and fluids. safely.
 Equipment safety requirements.  Applying maintenance
 Personal safety requirements. procedures.

 Exhaust systems  Communication.

 Service manual.  Ability to work in a team.

 Cleaning methods and materials.


 Principle of engine operation

26
UNIT TITLE Perform diesel engine tune-up.

DESCRIPTOR This unit covers competencies required to perform


diesel engine maintenance in order to keep the
vehicle in good running condition and optimum engine
performance, and to prevent serious engine trouble.

CODE 7231-U8-L2

ELEMENTS OF
PERFORMANCE CRITERIA
COMPETENCE

1. Service fuel 1.1 Check fuel injection system following


injection standard procedures
system.
1.2 Service fuel injection system following
standard procedures
1.3 Set injection timing in accordance with service
manuals.

2. Service drive 2.1 Check drive belt for tension and wear
belt. following standard procedures.
2.2 Adjust drive belt tension to specified tension
and replace if worn out following standard
procedures.

3. Check engine 3.1 Conduct compression test following standard


compression. procedures.
3.2 Interpret compression test result and carry out
necessary action following standard
procedures.

4. Check valve 4.1 Check valve tappet clearance as per service


tappet manual.
clearance.
4.2 Set valve tappet clearance as per the service
manual.

27
RANGE STATEMENT

Fuel injection Includes but not limited to:


system
Common Rail Direct Injection (CRDI) system, Fuel
Injection Pump (FIP) system, fuel filter, air cleaner,
injectors, fuel feed pump.

ASSESSMENT GUIDE

Form of assessment
 Continuous assessment together with collected evidence of
performance will be used.
 Evidence of the performance shall be based on practical
demonstration.
 Knowledge can be assessed through diagrams, in writing or orally
(viva-voce).
Assessment context
 Competency may be assessed in the actual work place or in a
simulated workplace setting.
Assessment condition
 The candidate shall have access to all required tools, equipment,
materials and documents.
 The candidate must complete the assessment in industry accepted time
frame.
Critical aspects
 Demonstrate compliance with safety regulations applicable to work site
operations.
 Perform diesel engine tune up following standard procedures.

28
UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS

 Types of fuel injection system.  Safe use of tools and


equipment.
 Basic electrical and electronics
 Applying maintenance
 Procedure of engine tune up. procedures.
 Types of lubricants and fluids.  Communication.
 Equipment safety requirements.  Ability to work in a team.
 Personal safety requirements.
 Cleaning methods and materials.
 Principle of engine operation.
 Interpretation of manual and
specification.

29
UNIT TITLE Perform basic auto electrical works.

DESCRIPTOR This unit covers competencies required to carry out


basic auto electrical work.

CODE 7231-U9-L2

ELEMENTS OF
PERFORMANCE CRITERIA
COMPETENCE

1. Inspect and 1.1 Inspect and service basic auto electrical


replace basic components for defects following standard
electrical procedures.
components.
1.2 Service defective parts in accordance with
manufacturer’s specifications.

2. Service 2.1 Take precautions to prevent loss or damage


batteries and of electrical components.
jump start
2.2 Test battery conditions following standard
vehicles.
procedures.
2.3 Analyze results and recommend remedial
action in accordance with standard
procedures.
2.4 Jump start vehicle following standard
procedures

RANGE STATEMENT

Basic auto Includes but not limited to:


electrical
Fusible linkages, starter motor, alternators, horn,
components
lighting equipment, wires, wipers.

Tests Includes but not limited:


Open circuit test, short circuit test, load test, specific
gravity test, cell voltage test.

Tools and Includes but not limited to:


equipment
Multimeter and test lamps, load tester, hydrometer,
30
battery charger, cell tester.

ASSESSMENT GUIDE

Form of assessment
 Continuous assessment together with collected evidence of
performance will be used.
 Evidence of the performance shall be based on practical
demonstration.
 Knowledge can be assessed through diagrams, in writing or orally
(viva-voce).
Assessment context
 Competency may be assessed in the actual work place or in a
simulated workplace setting.
Assessment condition
 The candidate shall have access to all required tools, equipment,
materials and documents.
 The candidate must complete the assessment in industry accepted time
frame.
Critical aspects
 Demonstrate compliance with safety regulations applicable to work site
operations
 Service basic auto electrical components following standard
procedures.

UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS

 Occupational Health and Safety  Identifying wire gauge or sizes.


(OHS) Regulations.
 Operating basic auto electrical
 Procedures of installing electrical system.
devices.
 Testing and fault finding.
 Operation of electrical system
and components relevant to  Reading and interpretation of

31
application. diagrams and circuits.
 Electrical principles and their  Handling battery.
application to wiring/lighting.
 Use of multimeter, hydrometer,
 National Environment load tester, voltmeter, ammeter,
Commission Act and regulations cell tester.
in relation to the disposal of
batteries and acids.  Use of hand tools.

 Safe handling of battery  Preventing loss of vehicle


electrolyte. electronic memory.

 Identification of battery types.


 Servicing and jump start
procedures.
 Battery charging procedures.

32
AUTOMOBILE MECHANIC
COMPETENCY STANDARDS
FOR
NATIONAL CERTIFICATE LEVEL 3 (NC 3)

UNIT TITLE ELEMENTS OF COMPETENCE

Overhaul engine 1. Diagnose problems and dismount engine.


2. Service engine.

33
UNIT TITLE Overhaul engine.

DESCRIPTOR This unit covers competencies required to carry out


engine overhaul and related maintenance.

CODE 7231-U10-L3

ELEMENTS OF
PERFORMANCE CRITERIA
COMPETENCE

1. Diagnose 1.1 Troubleshoot engine problems following


problems and standard procedures
dismount
1.2 Tag removable connections using specific
engine
codes following standard procedures
1.3 Dismount engine and components as per
service manual.

2. Service 2.1 Dismantle engine in accordance with the


engine. service manual.
2.2 Service engine components with
recommended solvents following standard
procedures
2.3 Recommend repair, rectification or any
necessary machining jobs following standard
procedures
2.4 Assemble the engine components and
aggregates as per the service manual.
2.5 Tests run the engine following standard
procedures.
2.6 Participate in road test following standard
procedures.

RANGE STATEMENT

Removable Includes but not limited to:


connections
Wires and cables, hoses, tubing and controls.

34
Engine Includes but not limited to:
components
Engine block, piston, connecting rods, main bearings,
connecting bearing, crank shaft, oil pump, oil
pressure, relieve valves, exhaust or intake valves,
cylinder liner, cylinder head, combustion chambers,
valve guide, valve seats, valve lifter, valve shims,
rocker arms, rocker shims, springs, oil nozzle.

ASSESSMENT GUIDE

Form of assessment
 Continuous assessment together with collected evidence of
performance will be used.
 Evidence of the performance shall be based on practical
demonstration.
 Knowledge can be assessed through diagrams, in writing or orally
(viva-voce).
Assessment context
 Competency may be assessed in the actual work place or in a
simulated workplace setting.
Assessment condition
 The candidate shall have access to all required tools, equipment,
materials and documents.
 The candidate must complete the assessment in industry accepted time
frame.
Critical aspects
 Demonstrate compliance with safety regulations applicable to work site
operations.
 Service and testing of engine following standard procedures

35
UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS

 Occupational Health and Safety  Reading, interpreting, and


(OHS) Regulations. applying service manual
instruction.
 Procedures of overhauling
engine.  Safe use of tools and
equipment.
 Operating principle of engine
and its components.  Use of consumable items.
 National Environment  Applying maintenance
Commission Act and regulations procedures.
in relation to the disposal of
hazardous waste materials.  Communication.

 Safe Handling of engine  Ability to work in a team.


components.
 Identification of types of engine.
 Measuring instruments and
equipment.
 Interpretation of manual and
specifications

36
Department of Occupational Standards
Ministry of Labour & Human Resources
Thongsel Lam, Lower Motithang
P.O. Box 1036, Thimphu.
Tel: 02-331611, Fax: 02-326873
37
www.molhr.gov.bt
38

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